CN110508907B - Gas shield automatic welding method and system for perforation plug welding joint - Google Patents
Gas shield automatic welding method and system for perforation plug welding joint Download PDFInfo
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- CN110508907B CN110508907B CN201910749906.6A CN201910749906A CN110508907B CN 110508907 B CN110508907 B CN 110508907B CN 201910749906 A CN201910749906 A CN 201910749906A CN 110508907 B CN110508907 B CN 110508907B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23K9/16—Arc welding or cutting making use of shielding gas
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Abstract
The invention discloses a gas shield automatic welding method and a system for a perforation plug welding joint, which comprises the following steps: identifying the plug welding holes and the outer contour of the steel bars, and dividing a gap between the outer contour of the steel bars and the plug welding holes into a plurality of areas; identifying a gap intermediate value and a dip angle of each region; and welding by adopting a multilayer and multi-pass welding process, and in the welding process, welding by adopting different welding parameters according to different welding layer channels, and gap intermediate values and inclination angles of different areas. The invention has the beneficial effects that: the method reduces the assembly difficulty, improves the efficiency and ensures the quality of the welding seam.
Description
Technical Field
The invention belongs to the technical field of gas shield welding, and particularly relates to a gas shield automatic welding method and system for a perforated plug welding joint.
Background
The statements in this section merely provide background information related to the present disclosure and may not necessarily constitute prior art.
The shielding factory building wall body board for the nuclear power station is perforated and plug welded to be in large quantity, and a single submodule reaches up to 3200. At present, manual gas shield welding is mainly adopted for welding, the existing similar automatic welding equipment mainly focuses on welding at a perforation plug welding horizontal position, the requirements of a welding joint on a gap must be uniform, and great inconvenience is brought to welding and assembly of constructors.
When the perforated plug welding joint is in an inclined position, the inclined plug welding joint relates to the ascending slope welding and the descending slope welding, a molten pool is influenced by gravity, iron flows downwards, uneven weld gaps are formed, the corresponding welding posture and the corresponding welding process need to be continuously adjusted to ensure the forming quality of a weld, the welding at the inclined position and the uneven gaps easily cause poor forming of the root of the weld, the molten pool flows downwards under the influence of the gravity to cause the sunken lower side of the upper side of the weld to protrude outwards, and the risk of incomplete fusion and poor final surface forming is increased.
Disclosure of Invention
In order to solve the problems, the invention provides a gas shield automatic welding method and system for a perforated plug welding joint, which can solve the problem that the welding is difficult when the welding inclined position and the assembly gap are not uniform in the prior art, and effectively ensure the internal fusion and the surface forming quality of a welding seam.
In some embodiments, the following technical scheme is adopted:
a gas shield automatic welding method for a piercing plug weld joint, comprising:
identifying the plug welding holes and the outer contour of the steel bars, and dividing a gap between the outer contour of the steel bars and the plug welding holes into a plurality of areas;
identifying the gap median value and the welding position inclination angle (namely the included angle between the workpiece and the horizontal plane) of each area;
and welding by adopting a multilayer and multi-pass welding process, and in the welding process, welding by adopting different welding parameters according to different welding layer channels, and gap intermediate values and inclination angles of different areas.
In other embodiments, the following technical solutions are adopted:
a gas shield automatic welding system for a piercing plug weld joint, comprising: the cantilever type automatic robot welding system comprises a robot body, a welding control system, a welding power supply and a welding gun with a vision system, wherein the welding control system and the welding power supply are arranged in the robot body, and the welding gun with the vision system is arranged at the tail end of an arm of the robot; the robot arm has 6 degrees of freedom.
Compared with the prior art, the invention has the beneficial effects that:
compared with the existing manual welding and semi-automatic welding processes, the method disclosed by the invention has the advantages that the assembly difficulty is reduced, the efficiency is improved, and the quality of a welding seam is ensured.
In the welding process, the flexible posture and visual recognition system based on the 6-axis degree of freedom solves the problems of root fusion and flowing under a weld pool through the methods of welding in different regions, adjusting the welding posture and welding process parameters.
The zonal welding can identify the gap conditions of different areas and automatically adapt to different welding parameters according to the gap, so that the deposition amount of different areas is adjusted and compensated, and the final welding seam surface forming is ensured.
The welded surface is beautiful, the residual height is less than 3mm, the root fusion is good, and no defect exists in the welding seam.
The welding system and the welding process provided by the invention are particularly suitable for plug welding of the through hole with the inclination of inclination below 15 degrees and the gap unevenness within 3 mm.
Drawings
FIG. 1 is a schematic view of a gas shield automatic welding system for a plug weld joint according to an embodiment;
FIG. 2 is a detailed view of a middle joint and a schematic view of the arrangement of the layer channels according to the first embodiment;
FIG. 3 is a schematic diagram of a welding process in a middle zone according to an embodiment.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
Example one
In one or more embodiments, a gas shield automatic welding system suitable for welding variable angle, variable gap, perforated plug weld joints is disclosed, as shown in fig. 1, comprising: horizontal migration track and set up the automatic welding system of cantilever type robot on the horizontal migration track, the automatic welding system of cantilever type robot includes: the robot comprises a robot body, a welding control system, a welding power supply and a welding gun with a vision system; the welding control system and the welding power supply are arranged in the robot body, and the welding gun with the vision system is arranged at the tail end of the robot arm; the robot body is equipped with lateral shifting axle and vertical movement axle, and the epaxial robot arm that connects of vertical movement, robot arm can drive welder and realize the motion of 6 degrees of freedom. In this embodiment, a direct current pulse gas shielded welding machine and a water-cooled welding gun are used.
In other embodiments, based on the above system, the gas shield automatic welding method for welding a perforated plug welded joint with a variable angle and a variable gap in the embodiment is specifically described by taking a perforated plug welded joint (steel bar diameter is 20mm, aperture is 25mm, and bevel angle is 45 °) of a nuclear power plant shielding workshop as an example, and includes the following steps:
(1) the steel plate is made of Q345B, the thickness is 20mm, the groove depth is 11mm, the groove angle is 45 degrees, and the diameter of a bottom hole is 25mm, as shown in figure 2. The steel bar material is HRB400E with the diameter of 20 mm. The welding gas is bottled protective gas (80% Ar + 20% CO2), and the gas flow is 16-18L/Min; the welding wire is ER80S-G, and the diameter of the welding wire is 1.2 mm.
(2) Carrying out sand blasting treatment on the steel bar, perforating the steel plate, processing a groove, wherein the angle of the groove is 43-47 degrees, and polishing and cleaning the surface; assembling the steel bars and the plug welding holes and performing tack welding, wherein tack welding points are arranged on the opposite sides of the grooves;
(3) identifying the plug welding hole and the outer contour of the steel bar through visual image identification, dividing the plug welding hole and the outer contour of the steel bar into 8 areas, and respectively identifying the gap intermediate value of each area; and the welding gun is adjusted to a position inclined by 45 degrees at the lower right as an arc starting position. And adjusting the included angle between the axis of the welding gun and the axis of the steel bar, namely the welding dip angle is 14-16 degrees, in the embodiment, the included angle is 15 degrees, and the tip of the welding wire is positioned at the center of the gap of the welding seam. As shown in fig. 3.
(4) The welding process adopts a robot direct current pulse gas shield welding process, adopts multilayer and multi-pass welding, and is divided into three parts of a bottom layer, a middle layer and a cover surface layer. The welding sequence is that the arc is started from the inclined 45-degree position at the lower right, the arc is welded for 180 degrees in a counterclockwise mode, then the arc is continuously welded for 180 degrees in a clockwise mode, and finally the arc is welded for 180 degrees in a counterclockwise mode. Different inclination angles and welding layer paths adopt different welding process packages, which are as follows:
priming a bottom layer: welding current is 180-200A; the welding voltage is 22-24V, the welding speed is 20-22 cm/min, the swing frequency is 1.9-2.1 Hz, the welding swing amplitude takes a middle value according to the gap of each area, the welding inclination angle is 14-16 degrees, and the advancing angle is 17-19 degrees. And (4) starting the arc for 0.9-1.1 s.
Filling layer: welding current is 180-200A; the welding voltage is 22-24V, the welding speed is 20-22 m/min, the swing frequency is 1.7-1.9 Hz, the swing amplitude is 3-4 mm, the welding inclination angle is 12-14 degrees, and the advancing angle is 4-6 degrees. The inner side stays for 0.1 to 0.3s, and the outer side stays for 0.3 to 0.5 s.
Covering the surface layer: the cover layer is divided into two processes according to the inclination angle:
the process when the inclination angle is in the range of 0-10 degrees comprises the following steps: welding current is 160-180A; the welding voltage is 22-24V, the welding speed is 22-24 cm/min, the swing frequency is 2.1-2.3 Hz, the swing amplitude is 6-7 mm, the welding inclination angle is 4-6 degrees, and the advancing angle is 4-6 degrees. The inner side stays for 0.1-0.3 s s s, and the outer side stays for 0.3-0.5 s.
The process when the inclination angle is in the range of 10 to 18 degrees is as follows: the welding speed of the upper half part is 18-20 cm/min, the swing frequency is 1.9-2.1 Hz, the swing amplitude is 6-7 mm, the inner side stays for 0-0.2 s, the outer side stays for 0.5-0.7 s, the welding inclination angle is 4-6 degrees, and the advancing angle is 7-9 degrees; the lower half part is welded at a speed of 22-24 m/min, a swing frequency of 1.9-2.1 Hz, a swing amplitude of 6-7 mm, a stay time of 0.1-0.3 s at the inner side and a stay time of 0.3-0.5 s at the outer side, a welding inclination angle of 4-6 degrees and a forward angle of 7-9 degrees. When the welding seam of the joint is more than three layers, the subsequent layer channel welding still adopts a surface layer process, and the amplitude can be adjusted only according to the width of the actual layer channel. Note: the amplitude range is (the width of the layer channel is +1)/2 to (the width of the layer channel is +3)/2 (the unit is mm).
In this embodiment, the specific welding parameters are selected as follows:
priming a bottom layer: welding current 190A; the welding voltage is 23V, the welding speed is 21cm/min, the swing frequency is 2Hz, the welding swing amplitude takes a middle value according to the gaps of all the areas, the welding inclination angle is 15 degrees, and the advancing angle is 18 degrees. The arcing stays for 1 s.
Filling layer: welding current 200A; the welding voltage is 23V, the welding speed is 20m/min, the swing frequency is 1.8Hz, the swing amplitude is 4.5mm, the welding inclination angle is 13 degrees, and the advancing angle is 5 degrees. The inner side stays for 0.2s, and the outer side stays for 0.4 s.
Covering the surface layer: the cover surface layer is divided into two processes according to the inclination angle, and the process of the inclination angle in the range of 0-10 degrees is as follows: welding current 180A; the welding voltage is 23V, the welding speed is 23cm/min, the swing frequency is 2.2Hz, the swing amplitude is 6.5mm, the welding inclination angle is 5 degrees, and the advancing angle is 5 degrees. The inner side stays for 0.2s, and the outer side stays for 0.4 s; the process when the inclination angle is in the range of 10 to 18 degrees is as follows: the welding speed of the upper half part is 18cm/min, the swing frequency is 2Hz, the swing amplitude is 6.5mm, the inner side stays for 0s, the outer side stays for 0.6s, the welding inclination angle is 5 degrees, and the advancing angle is 8 degrees; the lower half part has the welding speed of 23m/min, the swing frequency of 2Hz, the swing amplitude of 6.5mm, the inner side stays for 0.2s, the outer side stays for 0.4s, the welding inclination angle is 5 degrees, and the advancing angle is 8 degrees.
(5) Weld inspection
After welding, the welding seam surface is detected by 100% VT + 100% MT, and the defects of cracks, air holes, undercut and the like are avoided. And macroscopic metallographic detection is carried out after the perforated plug welding joint is thrown, the root fusion is good, no defect exists in the welding line, and the effective fusion depth of the welding line reaches more than 11 mm.
Although the embodiments of the present invention have been described with reference to the accompanying drawings, it is not intended to limit the scope of the present invention, and it should be understood by those skilled in the art that various modifications and variations can be made without inventive efforts by those skilled in the art based on the technical solution of the present invention.
Claims (5)
1. A gas shield automatic welding method of a perforation plug welding joint is characterized by comprising the following steps:
identifying the plug welding holes and the outer contour of the steel bars, and dividing a gap between the outer contour of the steel bars and the plug welding holes into a plurality of areas;
identifying a gap intermediate value and an inclination angle of each region;
welding by adopting a multilayer and multi-pass welding process, and in the welding process, welding by adopting different welding parameters according to different welding layer channels, and gap intermediate values and inclination angles of different areas;
the welding sequence is as follows: welding in an alternate manner of anticlockwise welding and clockwise welding from the arc starting position;
the position of the welding gun adjusted to a set angle is used as an arc starting position, the welding inclination angle is 14-16 degrees at the moment, and the tip of the welding wire is positioned at the center of a welding seam gap; the welding inclination angle is an included angle between the axis of the welding gun and the axis of the steel bar;
the multilayer and multi-pass welding process at least comprises the welding of a bottom layer, a middle layer and a cover layer.
2. A method of gas shielded automatic welding of a perforated plug weld joint as set forth in claim 1 wherein the welding parameters of said primer layer include: welding current is 180-200A; the welding voltage is 22-24V, the welding speed is 20-22 cm/min, the swing frequency is 1.9-2.1 Hz, the swing amplitude takes a middle value according to the gap of each area, the welding inclination angle is 14-16 degrees, the advancing angle is 17-19 degrees, and the arcing stays for 0.9-1.1 s.
3. A method of gas shielded automatic welding of a piercing plug weld according to claim 1, wherein the welding parameters of the intermediate layer include: welding current is 180-200A; the welding voltage is 22-24V, the welding speed is 20-22 m/min, the swing frequency is 1.7-1.9 Hz, the swing amplitude is 3-4 mm, the welding inclination angle is 12-14 degrees, the advance angle is 4-6 degrees, the inner side stays for 0.1-0.3 s, and the outer side stays for 0.3-0.5 s.
4. A gas shield automatic welding system for carrying out the gas shield automatic welding method of the piercing plug weld joint according to any one of claims 1 to 2, comprising: the cantilever type automatic robot welding system comprises a cantilever type robot body, a welding control system, a welding power supply and a welding gun with a visual system, wherein the welding control system and the welding power supply are arranged in the cantilever type robot body, and the welding gun with the visual system is arranged at the tail end of an arm of the cantilever type robot; the cantilever type robot arm has 6-axis freedom degree;
welding by adopting a multilayer and multi-pass welding process, and in the welding process, welding by adopting different welding parameters according to different welding layer channels, and gap intermediate values and inclination angles of different areas;
the welding sequence is as follows: and welding according to a welding mode that the set angle of anticlockwise welding and the set angle of clockwise welding are alternately performed from the arc starting position.
5. The gas shielded automatic welding system of claim 4, wherein the vision system is configured to identify the plug weld hole and the outer contour of the steel bar, divide the gap between the outer contour of the steel bar and the plug weld hole into a plurality of regions, and identify the gap median and the inclination angle of each region.
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| CN110977101B (en) * | 2019-12-13 | 2021-08-20 | 哈尔滨电机厂有限责任公司 | Method for automatically pulse MIG surfacing welding of aluminum bronze on upstream and downstream flanges |
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